Download none SH-904-UNF-30in Instructions / Assembly

Special Order Program
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MAIN DOOR CORPORATION LIMITED WARRANTY
Main Door Corporation warrants, subject to the
conditions and restrictions below, that its products
are free from defects in material and workmanship
for the period of one year beginning on the date of
purchase by the customer.
Should a Main Door Corporation product fail to
conform to this written warranty, Main Door
Corporation will, at its option, either:
1.
2.
3.
4.
Repair the product found to be defective free
of charge, or:
Provide a replacement part or parts to repair
the product found to be defective free of
charge, or:
Provide a replacement product in the same
condition of fitting and finishing as the product
that has been ordered originally, or:
Refund the original price received for the
product.
Main Door Corporation shall not be responsible for
any labor costs or other costs to remove defective
products or to retrofit new products or parts.
Main Door Corporation will not be held liable for any
product repaired or replaced without its prior written
consent.
Main Door Corporation shall not be responsible for
finishing costs of new products, unless purchased
factory finished from Main Door Corporation and
with its prior written consent to pay for those costs.
THE FOLLOWING SHALL NOT BE CONSIDERED DEFECTS
IN MATERIAL OR WORKMANSHIP AND ARE NOT
COVERED BY THIS WARRANTY:
1.
2.
3.
Warp for any door wider than 42" or taller than
96";
Warp for any nominal 1-3/4" thick by 42" wide by
96" high or smaller door, not exceeding 1/4" in
the plane of the door itself;
Bow or nonalignment in the frame or jamb in
which the door is hung if such is purchased from
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4.
5.
6.
7.
8.
Main Door Corporation not machined and not
prehung;
Variations or unsatisfactory results in gloss level,
texture or appearance resulting from the field
application of paint or any other finishing
material;
Our products are primarily manufactured with
wood. Wood, by its nature, has natural
variations in color. These variations are
considered enhancements and are not defects.
All pieces of wood are unique. Some pieces of
wood have more pronounced grain patterns
than others. When pre-finished, the differences
may be more pronounced and are not defects
in the wood or finish. Additionally, bleed-through
of wood pitch may be experienced – this is not
considered a defect.
Damage caused by others or by any cause
beyond the control of Main Door Corporation,
including, but not limited to: damage caused by
misuse, abuse, accident, mishandling or by fire,
flood, earthquake, storm, tornado or other acts
of nature.
"Misuse" of a door includes, but is not limited to,
using a door on part of a building without
providing
adequate
overhang
or
an
appropriate finish color. Adequate overhang
depends on the typical weather conditions of
the area where the door is to be used, but
typically means an overhang projecting a
distance from the structure one half the
elevation difference between the bottom of the
door and the base of the overhang structure at
the point which is farthest from the door. In order
to reduce the chance of warping or checking,
dark colored finishes should be avoided on all
surfaces, especially on light colored wood
species, or if the door is exposed to direct
sunlight;
Damage due to trimming more than ½’’ from
the top or 1 ½’’ from the bottom and cutting
into dowels;
Failure to perform normal homeowner'
s
maintenance, including maintaining the finish
(factory finish or non-factory finish);
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9.
10.
11.
12.
13.
14.
Product failure due to improper or incorrect
installation;
Attempts to repair Main Door Corporation
products other than by Main Door Corporation
representatives;
Panel movement (shrinkage) of 1/4" or less.
Wood doors are susceptible to expansion and
contraction caused by temperature and
humidity variations. These may cause the wood
panels, that have been designed to "float", to
shrink, leaving an unstained line along the panel
edge and tiny cracks at the joints. These
deviations from perfection are not considered
flaws. While Main Door Corporation doors are a
low-maintenance product, field touch-up may
be required due to environmental conditions,
dings, dents and the normal expansion and
contraction of wood. Main Door Corporation
takes extra measures to ensure that joint
separation is minimal. However, it is normal to
experience some joint separation in areas where
stiles and rails meet and at casing joints. These
are not considered defects. If joint separation
occurs, the separated area must be sealed.
Stains and fillers are available in all standard
colors from Main Door Corporation.
Damage caused by extreme temperature
buildup where a storm door is utilized. Storm
doors must be vented to eliminate this
temperature buildup;
Slight expansion or contraction due to varying
environmental conditions, such as temperature
and humidity;
Doors shipped out of the continental Untied
States or Hawaii are not warranted. This
Warranty applies only if the Main Door
Corporation product is installed in a structure
located within the United States of America.
Main Door Corporation does not warrant any
product, which is installed outside the United
States or Hawaii. This Warranty applies only to
products as originally installed in the customer’s
building and does not apply to any tear outs
and reinstallations.
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The exterior finish is warranted for a period of one (1)
year from the date of purchase against cracking,
peeling, checking or delaminating subject to the
following terms and exclusions: Defects not covered
under this Warranty include, but are not limited to:
failures related to knots, finger-joints, stile and rail
separation, cracking or failure of the substrate,
improper installation and maintenance, moisture
penetration, or improper cleaning. Should the finish
fail, and the conditions set forth herein have been
satisfied, Main Door Corporation will provide the full
cost of replacement finishing during the first year of
this Warranty. In the event that a failure occurs, Main
Door Corporation, reserves the right to determine the
best method needed to correct the situation,
including, but not limited to, the refinishing in the field
of the failed part(s). In order for the Warranty to be in
effect, Main Door Corporation must be notified in
writing of the failure within thirty (30) days of the
discovery
of
such
problem
and
provide
documentation. Main Door Corporation may require
clear pictures of the affected product. If Main Door
Corporation chooses to repaint, we will use normal
repainting practices including a trade paint product
or other suitable alternatives. The Warranty also
applies to any part we repaint/refinish, repair, or
replace, but only for the unexpired portion of the
Warranty period applicable to the original part.
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Solid wood entry door Installation Instructions
Materials for Installation:
Touch-up stain / paint wax crayon [included w/ finished
units only]
Shims [not included]
Caulking [not included]
Sandpaper Grid 150 [not included]
Casing or finish nails or # 8 X 3” and 2-1/4” drywall screws
[not included]
Lockset [not included]
Primer or sanding sealer in case of unfinished units. [not
included]
Tools for Installation [not included]:
Tape measure
Level
Hammer
Caulking gun
Square
Screwdriver
Power drill
Miter saw
For safety reasons it is recommended to use safety
glasses and safety gloves when working with power
tools. To install any prehung door unit larger than a
single door unit, two people are required.
Before starting the installation of any door unit, read
Installation instructions carefully and check all
necessary parts and tools needed [for list of tools and
parts needed see above]. Note: these Instructions do
not claim to be complete and different methods of
door installation might be possible.
Getting started:
1.
2.
Check the rough opening of door. For the
majority of installations, the distance between
the left and right stud and the distance
between the header and the floor should be
about ½” to 1” wider and taller than the door
unit’s overall width and height.
All Main Door Units come when purchased as
Prehung with ether a 1-3/16” height Aluminum
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3.
4.
5.
6.
7.
8.
9.
Oak Adjustable or a 1-1/4” Solid oak sill. Both
provide adequate clearance for most floors,
such as carpet, wood and tile. In case you need
an even height clearance, the rough opening
must be adjusted.
Prior to installation check the rough opening to
ensure that:
The opening provides enough space a
properly shimmed.
The opening is not twisted. Minor twist can
be corrected with shims. If the opening is
badly twisted [not plum], you will have to fix
the condition before proceeding.
Prehung door units are shipped out by Main
Door Corporation standing upright on a pallet,
covered with white cardboard. Prior to
installation, make sure that the unit is delivered
in good condition.
For installation, take the door (s) off the hinges
by removing the hinge pins. Once the doors are
removed, take the unit off the pallet and
remove all package parts from the frame.
Prepare threshold area of the door unit by
putting two generous lines of caulking about ½”
in distance to each other along the outer edge
of the floor. It is important to make sure that the
caulking beads will seal the floor and the
threshold against moisture entering from the
outside.
Proceed with installation by carefully tilting the
door into the door opening. Make sure that the
previously applied caulking has contact with the
threshold and that the hinge jamb leg is level.
Replace one screw from the top and bottom
hinge plate by a # 8 x 3” screw to temporarily
fasten the jamb loosely into the stud. Or, remove
the hinge plate and place screw behind the
hinge plate to temporarily fasten the jamb
loosely into the stud.
Once the jamb is only fastened loosely, you can
now begin to shim the hinge jamb from the
inside behind the hinge location. Be sure that
the hinge jamb leg is level in both directions and
the entryway opening is square.
Once the hinge jamb leg is fixed in a level and
square position, start leveling and shimming the
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10.
11.
12.
13.
latch jamb leg in a square position. It is
recommended to place a minimum of three
shims between the stud and the jamb leg.
Remove the Q-lon Weather stripping and
temperately fasten the jamb about 2” from the
top and from the bottom in an area that once
the Q-lon is reinstalled will be covered with # 8 X
3” Drywall Screws. When installing a single door,
do not shim and fasten the top of the unit. If you
are installing a prehung unit that has sidelites,
shim and fasten the top of the unit where the
sidelite joins the doorjamb.
After rechecking that the hinge jamb is still level
and square, secure the jamb leg in place. Make
sure that the door opens freely and the space
between the door and the jamb is level on all
sides. Be sure that the Q-lon meets and seals the
door on all sides evenly, so when closed no light
comes through. Adjust if necessary. In case of
adjustments, loosen or remove the latch jamb
fasteners and adjust the latch jamb until there is
even contact with the weather stripping.
Reassure that the door shoe touches the
threshold evenly. Most doors have an oak
adjustable aluminum threshold; in this case, you
can make corrections by adjusting the
adjustment screws on the top of the oak strip.
These allow you an adjustment of maximum ¼”;
in addition to the adjustment at the threshold,
you can lower the door sweep by 1/8” by
loosening its screws and pulling the door sweep
down.
If you have ordered the unit with a solid oak sill,
you can adjust the threshold contact by
adjusting the squareness of the door unit and
lowering the door shoe.
Recheck for smooth operation and even
spacing between the door and the jamb.
Secure the latch and the hinge jamb in place
If you have a double door. some additional
fastening is required. Double doors should be
secured through the jamb head and into the
door header with two 10D finish nails or two # 8 x
3” drywall screws. DO NOT SHIM THE TOP OF THE
JAMB HEAD!
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Below are some of the most common problems
faced when installing DOUBLE DOORS
Troubleshooting tips for installing double door and all
Prehung units
when installing prehung units particularly double
door units; there are certain problems that may arise.
Generally, the larger the opening, the more likely it is
to be out of square. When installing units into an
existing opening, it may not be sufficient enough to
align the jambs with the existing framing. If the
existing framing is out of square and the prehung unit
is aligned with the existing framing, then the prehung
unit will also be out of square. Problems with
alignment can happen with any prehung unit but
the problems are enhanced with double door units
due to the extra door.
Here are some solutions to the common problems of
installing double door units. These solutions can also
be used with other prehung units.
Problem No. 1: Doors don’t align at top
Prehung Unit out of
square (exaggerated
to show the problem)
Doors aligned at top and
bottom
SOLUTIONS
Shim at Points A, B and, or C. If there is sufficient
spacing on the opposite sides of point A and B
then shim at points A and B to shift frame and
align doors at top and bottom. If there isn’t, shim
at point C to lift up side and align doors
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Problem No. 2: Doors don’t close together evenly.
SOLUTION:
Frame has to be shifted at point A, B, C and/ or
D. Shift point A forward or right. Shift point B
backward or left. Shift point C backward or left.
Shift point D forward or right. Use any of these
combinations in order to align doors. If doors are
only slightly out of alignment the ½” hole for flush
bolt can be drilled either forward or backward
of center slightly.
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Problem No. 3 Step from jamb to framing
Step from jamb to
Step from jamb to framing on the
inside. The casing has to be back cut.
framing on the outside.
The brick mould has to be
back cut.
SOLUTIONS:
If jambs are shifted to
the point that there is
a step from jamb to
framing, then the
casing or the brick
mould will have to be
back cut in order to
install the moulding
correctly (see
examples).
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Provided Brickmould and Casing
Backcut Brickmould and Casing
14. Touch up any nail holes by rubbing the
delivered (factory finished units only) crayon into
the nail holes and rub off excess with a clean
rack. For unfinished units, use wood putty to
touch up nail holes.
15. Caulk around the outside of the door unit
between the siding and the brick mould, along
the front side of the threshold and between the
jamb sides and the threshold.
FAILURE TO FOLLOW PROPER INSTALLATION AND
FINISHING INSTRUCTIONS WILL VOID THE WARRANTY!
FINISHING INSTRUCTIONS:
Before getting started, here are some helpful hints:
Wear safety glasses for eye protection, and rubber
gloves to avoid skin irritation.
Always follow paint or stain manufacturers’
instructions.
Ask your local hardware / paint store for the best
quality materials and make sure that all materials
are compatible with each other.
Never finish only one side of the door.
Always allow material used enough time to dry
Seal and finish all six sides of a door.
Remove hardware from door and mask off glass
prior to finishing.
Finish in a dust free, well-ventilated environment,
away from the sunlight.
STAIN- Finishing instructions
When working with finishing materials, always follow
the instructions of the material’s manufacturer.
Always keep finishing materials out of reach of
children.
1.
2.
3.
4.
Lightly block sand the surfaces of the unit with
sandpaper 150 grit in the direction of the wood
grain. Never sand cross grain!
Clean unit from all dust.
Check all surfaces to be clean and smooth.
Apply stain with a brush or cheesecloth evenly in
direction of the grain. Wipe off excess stain to
achieve the desired color and grain effect. After
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5.
the door is stained allow material to dry. Follow
instructions of the stain manufacturer.
Apply a minimum of two coats of clear
Polyurethane or Varathane. Spray applications
will achieve the best results. Make sure the door
is sealed on all SIX sides.
Follow the same procedure to stain other parts of the
unit, e.g., jamb sets or moldings.
FAILURE TO FOLLOW PROPER FINISHING INSTRUCTIONS
AND ADEQUATE PROTECTION FROM WEATHER WILL
VOID THE WARRANTY!
PAINT- Finishing instructions
1.
2.
3.
4.
5.
Lightly block sand the surfaces of the unit with
sandpaper 150 grit in the direction of the wood
grain. Never sand cross grain!
Clean unit from all dust.
Seal door with quality primer on all six sides.
Allow primer to dry thoroughly(check instructions
of manufacturer)
Sand lightly with Sandpaper 320 grit and clean
off dust. Apply second coat of primer. Make
sure to use compatible materials.
After drying, sand with sandpaper 320 grit, clean
off dust and apply one even coat of to paint.
FAILURE TO FOLLOW PROPER FINISHING INSTRUCTIONS
AND ADEQUATE PROTECTION FROM WEATHER WILL
VOID THE WARRENTY!
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Maintenance and frequent asked questions
Exposure
Exposure to the elements, such as sun, wind, rain and
any type of moisture will affect any well-finished
exterior wood product.
In order to preserve the beauty of your door and its
protective finish, it is recommended to read the
following:
It is recommended to inspect the door at least once
a year, and refinish if necessary. It is considered
normal maintenance to refinish the topcoat
approximately once a year.
To maintain the topcoat it will not be necessary to
strip the door! To refinish, the unit must be cleaned
off all dust and residue given a light sanding the
direction of the grain with 220-grit sandpaper. After
sanding, wipe off all dust in the sanded areas.
Thoroughly read and follow all instructions provided
by the topcoat manufacturer on the can and apply
accordingly.
Depending on the environment in which the door is
installed, refinishing might be required every 1 to 3
years.
How should the door be cleaned?
The first step in maintaining the finish of the door
should be keeping it clean from dust, as dust holds
and absorbs moisture on humid days. But not only
does dust trap moisture, it also holds a high
concentration of smog and pollution, which can act
together with the moisture, like an acid, affecting the
finish if not removed on a regular basis.
Therefore, use a dust cloth, just like the one you use
to clean furniture. After dusting the door, we do not
recommend using any furniture polish, as those might
affect the finish.
Never use solvents, abrasive cleaners, detergents or
soaps for cleaning; these might destroy the finish of
your door. Do not wash the door with water or rinse it
off with a hose, as this might lead to swelling of the
door. We do not recommend the use of heavy
waxes as they leave a residue.
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Will it be necessary to reseal the wood after trimming
sanding or planing?
Your door whether finished or unfinished will require
an additional sealing on any side that has been cut,
sanded or planed.
By cutting, sanding or planing finished door units
during the process of the installation, you break the
seal that has been applied by the factory. This seal
needs to be reapplied to the door to give it the
protection against moisture reentering or, in a dry
environment, evaporation out of the pores of wood.
For products purchased unfinished, you will have to
seal the whole unit. Never expose unsealed, raw
wood to the environment.
An example of the effects of moisture on wood:
•
A 12” wide oak board that changes from
8% moister content to 4% moister content
will shrink up to 3/16”! [12” 0.00369*4% 0.17712”+11/64” based on the Wood
Engineering Handbook by the U.S. Forest
Products Laboratory] Even though the
shrinkage of species other than oak is
different, the basics are the same.
This is why it is very important to seal the pores of the
wood carefully prior to installation and it is always a
good idea to check the top and bottom edge of
your door for proper sealing.
How to touch up nicks and scratches.
As time goes by, your door might get minor nicks and
scratches. That is why Main Door Corporation
provides every customer who purchased a finished
unit with a touch up kit. This kit contains some stain
and a touch up pen. If you have applied a finish
other than the factory finish, we recommend that
you keep on hand a small quantity of stain and
sealer to repair small nicks and scratches.
After applying the stain, allow the area to dry for
approximately 2-4 hours. After the stain is dry, use an
artist’s brush to apply a first coat of varnish. We
recommend using an oil-based Polyurethane varnish
in semi gloss for stained units. After applying the first
coat, let the area dry for at least 1 to 2 hours before
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an intermediate light sanding (use sandpaper P 320)
and the application of the second coat.
What happened if there is an unstained line around
the panel showing?
This line is caused by the contraction of the wood
panel. As wood is a hygroscopic, natural product it
reacts to changes of its environment and the
changing conditions of the climate. The doors
therefore are constructed with free-floating wood
panels to minimize cracking of the wood. If the
panels would be nailed or glued in place, the power
of the contracting (or expanding in humid climates)
panel would cause severe cracks and damages to
the door.
As a matter of fact, the power of the expansion of
wood is so strong that it was used in ancient Egypt to
break stones for the construction of the pyramids. As
there was no dynamite available, Egyptian miners
drove dry wood into a rock, added water and
waited until the expanding wood cracked the rock.
Lines around the panel can be touched up very
easy. First, clean the area of all built ups and easy to
remove varnish. Once this is done, stain the
unstained raw wood. Use a fine brush to apply the
stain. After the application of the stain wipe off the
excess and let the stain dry slowly for 2-4 hours. After
the stain is dry, use an artist’s brush to apply a first
coat of varnish. We recommend using an oil-based
Polyurethane varnish in semi gloss for stained units.
After applying the first coat, let the area dry for at
least 1 to 2 hours before an intermediate light
sanding (use Sandpaper P 320) and the application
of the second coat.
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